Electric drive pump for well stimulation

ABSTRACT

An electric drive hydraulic fracturing pump system includes one or more electric motors, with each electric motor electrically coupled to a dedicated dual inverter to control operation of the motor. A plurality of electric motors may be coupled to each end of a pump crankshaft and configured to provide rotational power to the power end of a hydraulic fracturing pump through a planetary gearset coupled to each end of the crankshaft. A hydraulic cooling circuit having a first and second cooling systems may be used to regulate the temperature of the electric motors and dual inverters.

PRIORITY

The present application claims priority to U.S. Provisional ApplicationNo. 62/909,082, filed Oct. 1, 2019, the benefit of which is claimed andthe disclosure of which is incorporated herein by reference in itsentirety.

TECHNICAL FIELD

The present application relates generally to hydraulic fracturing in oiland gas wells, and in particular to an electric drive pump used to drivea fluid end for the pumping of a fracturing fluid into a well.

BACKGROUND

It is difficult to economically produce hydrocarbons from lowpermeability reservoir rocks. Oil and gas production rates are oftenboosted by hydraulic fracturing, a technique that increases rockpermeability by opening channels through which hydrocarbons can flow torecovery wells. Hydraulic fracturing has been used for decades tostimulate production from conventional oil and gas wells. The practiceconsists of pumping fluid into a wellbore at high pressure (sometimes ashigh as 50,000 PSI). Inside the wellbore, large quantities of proppantsare carried in suspension by the fracture fluid into the fractures. Whenthe fluid enters the formation, it fractures, or creates fissures, inthe formation. Water, as well as other fluids, and some solid proppants,are then pumped into the fissures to stimulate the release of oil andgas from the formation. When the pressure is released, the fracturespartially close on the proppants, leaving channels for oil and gas toflow.

Fracturing rock in a formation requires that the fracture fluid bepumped into the well bore at very high pressure. This pumping istypically performed by high pressure, hydraulic fracturing pumps, with adiesel engine used to power operation of the pump to deliver fracturefluids at sufficiently high rates and pressures to complete a hydraulicfracturing procedure or “frac job.” While such hydraulic fracturingpumps are able to pump fracturing fluid into a well bore at a highenough pressure to crack the formation, they also have drawbacks. Forexample, the diesel powered pump systems are very heavy, and thus mustbe moved on heavy duty trailers, making transport of the pump systemsbetween oilfield sites expensive and inefficient. In addition, thediesel engines required to drive such pumps require a relatively highlevel of expensive maintenance. Furthermore, the cost of diesel fuel ismuch higher than in the past, meaning that the cost of running the pumpsystems has increased.

To avoid the disadvantages of diesel-powered hydraulic fracturing pumpsystems, electrically powered hydraulic fracturing pump systems havebeen proposed. Some prior art systems offer a dual electric motorconfiguration coupled to one or two triplex pumps. This large,industrial-sized, and air-cooled hydraulic fracturing pump system can becapable of 3600-4500 hydraulic horsepower (HHP). Other prior art systemsemploy a single electric motor configuration, wherein a centrallylocated motor is connected by two quintuplex pumps via a through-spindledesign. This larger prior art hydraulic fracturing pump system is alsoair-cooled, and is capable of 6000 HHP. Existing prior art electricconfigurations experience inefficiencies in certain key areas.Contemporary offerings for electric frac configurations are composed ofexisting components from mechanical systems that are repurposed forelectric applications. These components were not specifically built forelectric systems. Consequently, effective horsepower is decreased due todesign conflicts introducing hydraulic and mechanical resistance, aswell as accelerated wear cycles as a result of violent harmonics andmisalignments in provisional electric systems.

Additionally, the inefficiencies stem from the fact that air-coolingsolutions often are not capable of regulating the temperatures of theselarge electric motor systems, especially in environments where heat is aspecial concern. This leads to motors running hotter, and therefore, farless efficiently, which reduces the effective hydraulic horsepower ofthe entire hydraulic fracturing pump system. The inability to regulaterunning temperatures can also lead to premature failure.

There are other concerns regarding the integration of existingmechanical components and electric motors, such as the optimization ofthe ratios used by power end reduction gears. Electric motors are oftenmistakenly considered to produce the same results at any RPM. Eventhough they have flatter and more consistent torque and power curvesthan internal combustion solutions, this is not entirely true. Electricmotors do perform best within a certain RPM range, and contemporaryofferings have not taken full advantage of the optimization thatunderstanding provides. Reduction gear ratios that were not chosen foruse in a specific electrical application expose motors that drive themto possible premature failure, whether it be from spinning outside ofthe optimal range or introducing harmonic imbalances and damaging thepowertrain as a whole.

Although great strides have been made with respect to the power end of afracturing pump system, there clearly is room left for improvement inelectric drive pump fracking systems.

BRIEF DESCRIPTION OF THE DRAWINGS

For a more complete understanding of the present disclosure and itsfeatures and advantages, reference is now made to the followingdescription, taken in conjunction with the accompanying drawings, inwhich:

FIG. 1a is a schematic illustration of an electric hydraulic fracturingpump systems according to embodiments of the present disclosure;

FIG. 1b is a schematic illustration of the overall architecture of theelectric hydraulic fracturing pump system of FIG. 1 a;

FIG. 2 is a schematic illustration of the electrical architecture of anelectric hydraulic fracturing pump system;

FIG. 3 is a schematic illustration of the cooling circuit architectureof an electric hydraulic fracturing pump system of FIG. 2;

FIG. 4 is a is a schematic illustration of one embodiment of a powertransmission system of the electric hydraulic fracturing pump system;

FIG. 5a is front perspective view of an electric hydraulic fracturingpump system according to embodiments of the present disclosure;

FIG. 5b is an alternative perspective view of the electric hydraulicfracturing pump system of FIG. 5 a;

FIG. 6a is a perspective view of the electric motor and dual inverterarrangement of embodiments of an electric hydraulic fracturing pumpsystem;

FIG. 6b is an end view of the electric hydraulic fracturing pump systemof FIG. 6 a.

FIG. 6c is an alternative perspective view of the electric hydraulicfracturing pump system of FIG. 6 a.

DETAILED DESCRIPTION

It is an object of the present application to provide an electrichydraulic fracturing drive pump system for use in well stimulation. Theelectric hydraulic fracturing drive pump system is configured to providea plurality of individual motors and individual dual inverters inselective configurations that work together to provide power to a powerend. Each electric motor is controlled by its own dual inverter. Theelectric motors are coupled to a gearbox which is used to convert therotary motion of the electric motors into linear motion for operation ofthe plungers in the fluid ends of hydraulic fracturing pumps. Each dualinverter is utilized to convert a DC power signal from a power sourceinto an AC signal, and thereafter, applies pulse width modulation to theAC signal to control flow and torque of its associated electric motor.The electric hydraulic fracturing drive pump system includes atransmission assembly that is composed of the gearbox and the pluralityof electric motors. The transmission assembly is attachable to any powerend and is operable with legacy power ends.

Because of the amount of heat generated by the dual inverters, as wellas the electric motors, a cooling circuit having parallel dual coolingsystems, with one cooling system regulating temperature of the motorsand the other cooling system regulating temperature of the dualinverters.

The system in accordance with the present application overcomes one ormore problems commonly associated with conventional pumps used tostimulate a well. The electric drive pump system of the presentapplication is configured to incorporate a plurality of electric motorsto the power end or pump portion of a pump system and a correspondingnumber of dual inverters, where each dual inverter controls a separateelectric motor. The motors are configured to operate either collectivelyor independently to vary the power supplied to the power end. Theelectric motors may operate in any combined manner and may operate inany sequential order. The individual dual inverters control torque oftheir related motors to regulate power output of each motor. Byincluding smaller motors, the motors are more easily obtained in themarket, precise power requirements may be met smoothly, and overallpower consumption may be minimized.

Referring to FIG. 1 in the drawings, a schematic of an electric drivehydraulic fracturing pump system 100 for well stimulation through apower end is provided. The electric drive hydraulic fracturing pumpsystem 100 includes a hydraulic fracking pump 101 having a power end 103and a fluid end 108, a transmission assembly 105, a control module 107,a dual inverter assembly 110 and a temperature regulation circuit 109.Power end 103 is configured to convert, via a crankshaft 104, therotational/rotary motion generated through transmission assembly 105into a linear motion for operation of plungers 106 within one or morefluid ends 108. Power end 103 may operate with any number of fluid ends108 of hydraulic fracturing pumps 101 and may be constructed from acasting or fabricated from one or more materials. In one or moreembodiments, the crankshaft 104 extends between a first end 104 a and asecond end 104 b with a transmission assembly 105 directly coupled toeach end 104 a, 104 b of crankshaft 104 in order to balance torqueapplied to crankshaft 104 and maximize power input.

Transmission assembly 105 may be releasably mounted to power end 103 ofpump 101. In one or more embodiments, transmission assembly 105 includesat least one electric motor 111 electrically coupled to dual inverterassembly 110 having at least one dual inverter 112. In otherembodiments, transmission assembly 105 includes at least two, and insome embodiments, a plurality of electric motors 111 and a gearbox 113in communication with the two or more electric motors 111. In one ormore embodiments, a transmission assembly 105 is coupled to each end ofcrankshaft 104 and each transmission assembly 105 includes at least oneelectric motor 111 electrically coupled to its own dual inverter 112. Insome embodiments, each transmission assembly 105 includes at least threespaced apart electric motors 111, each electrically coupled to its owndual inverter 112. Thus, in some embodiments, three or more electricmotors 111 may be coupled to each end of the crankshaft. In someembodiments, each transmission assembly 105 includes at least fiveelectric motors 111 spaced apart about the axis of the crankshaft 104each of the electric motors 111 electrically coupled to its own dualinverter 112. In one or more embodiments, the transmission assembly 105coupled to each end of the crankshaft 104 has the same number ofelectric motors 111.

Gearbox 113 includes a gearset 114 for transferring rotational energyfrom the two or more electric motors 111 of a transmission assembly 105to the power end 103. Although the disclosure is not intended to belimited to a particular arrangement of gearset 114, in one or moreembodiments, gearset 114 includes at least one planetary gearset coupledto crankshaft 104. Such a planetary gearset 114 permits each individualelectric motor 111 to be spaced apart from the axis of the crankshaft104. In some embodiments, gearset 114 includes a bull gear attached tocrankshaft 104 and a plurality of separate planetary gearsets coupled tothe bull gear, where each of the planetary gearsets is coupled to aseparate electric motor 111. In other words, each electric motor 111drives a separate planetary gearset, and each of the separate planetarygearsets is then coupled to the bull gear. As used herein, the term“coupled” may include both direct attachment as well as meshed with agear via one or more other gears.

Although dual inverter assembly 110 need not be, in one or moreembodiments, dual inverter assembly 110 is mounted adjacent transmissionassembly 105 about the axis of crankshaft 104. In this regard in one ormore embodiments, a dual inverter 112 may be mounted directly to itscorresponding electric motor 111 in order to minimize the footprint ofelectric drive hydraulic fracturing pump system 100 since space at awell site is limited. In one or more embodiments, dual inverter assembly110 includes at least two, and in some embodiments, a plurality of dualinverters 112, each dual inverter 112 electrically coupled to a separateelectric motor 111. In one or more embodiments, a dual inverter assembly110 is mounted at each end of crankshaft 104 and each dual inverterassembly 110 includes at least two dual inverters. In some embodiments,each dual inverter assembly 110 includes at leak three spaced apart dualinverters 112. In some embodiments, each dual inverter assembly 110includes at least five dual inverters spaced apart about the axis of thecrankshaft 104. In one or more embodiments, the dual inverter assembly110 coupled to each end of the crankshaft 104 has the same number ofdual inverters 112.

Electric drive hydraulic fracturing pump system 100 may also include acontrol module 107 configured to regulate performance of transmissionassembly 105 and dual inverter assembly 110. Electrical power isprovided by dual inverter assembly 110 to electric motors 111, which inturn are used to induce a torque of selected power to rotate gearset 114within gearbox 113. Control module 107 is used to monitor theperformance of each electric motor 111 and each dual inverter 112, andcontrol selected functions of each electric motor 111, such as poweroutput, speed, on/off, unit temperature, and so forth via each motor'scorresponding dual inverter 112. It is understood that these areexemplary in nature and do not form an exhaustive listing of performancecharacteristics or functions that module 107 may regulate with respectto electric motors 111 dual inverters 112 or electric drive hydraulicfracturing pump system 100. Thus, in one or more embodiments, controlmodule 107 may also be utilized to control a temperature regulationcircuit 109 having a first cooling system 118 and a second coolingsystem 120. Through control module 107, electric motors 111 and dualinverters 112 can be controlled simultaneously as a group at selectedpower levels as desired and/or individually wherein each electric motor111 and each corresponding dual inverter 112 is independent of theoperation of other electric motors 111 and dual inverters 112 withrespect to at least torque, power output and runtime. Use of a pluralityof electric motors 111 and dual inverters 112 allows for simplificationof maintenance since one or more electric motor 111-dual inverter 112pairs may be selectively deenergized for maintenance while otherselectric motor 111-dual inverter 112 pairs remain energized foroperation of power end 103.

In one or more embodiments, dual inverters 112 may be provided withpower from a power source 122, such as the generator shown in FIG. 1b .In other embodiments, power source 122 may be battery stacks or directfeed from a main power grid.

As seen in FIGS. 1a and 1b , either one or two transmission assemblies105 may be coupled to drive power end 103. Electric motors 111 oftransmission assemblies 105 can be configured to operate in a clock-wise(CW) direction or a counter clock-wise (CCW) direction so as tocollectively rotate in the same direction relative to power end 103.Although electric motors 111 may be arranged in any manner withintransmission assembly 105, in one or more embodiments, electric motors111 may be symmetrically spaced about the axis of crankshaft 104. One ormore electric motor 111 may be in direct communication with the gearset114 of gearbox 113, which is directly coupled to crankshaft 104.

Temperature regulation circuit 109 is configured to regulate thetemperature levels of various components of electric drive hydraulicfracturing pump system 100, particularly the electric motors 111 and thedual inverters 112. In one or more embodiments, temperature regulationcircuit 109 is a cooling circuit having a first cooling system 118disposed to cool electric motors 111 and a second cooling system 120disposed to cool dual inverters 112. First cooling system 118 circulatesa first coolant fluid while second cooling system 120 circulates asecond coolant fluid. In one or more embodiments first coolant fluid isa synthetic coolant and second coolant is a mixture of water and glycol.

With reference to FIG. 2, each dual inverter 112 may include an ACterminal for receiving an alternating current (AC) signal from a powerdistribution module 121 electrically coupled to power source 122. InFIG. 2, five electric motors 111 a-111 e are illustrated, along withcorresponding dual inverters 112 a-112 e. In this regard, the powerdistribution module 121 may be disposed to receive an AC signal frompower source 122. In any event, each dual inverter 112 a-112 e includesa high voltage direct current (DC) terminal for transmitting theconverted AC signal. A first line out from the high voltage DC terminalmay be electrically coupled to one or more converters 124 to convert thehigh voltage DC signal to a low voltage DC signal for driving one ormore auxiliary electrical components 128, such as fans or pumps. In oneor more embodiments, the low voltage DC signal from converter 124 may bedirected through a low voltage DC splitter 127 to a plurality ofauxiliary components 128. The first line out from the high voltage DCterminal may be electrically coupled to one or more inverters 125 toconvert the high voltage DC signal to an AC signal for driving one ormore auxiliary electrical components 126, such an oil motor. Withreference to FIGS. 1b and 2, the first line out from the high voltage DCterminal may be directed through a high voltage DC splitter 123 to aplurality of inverters 125, a plurality of converters 124, or to atleast one inverter 125 and at least one converter 124. In someembodiments, at least one high voltage DC splitter 123 may be suppliedon each end of the crankshaft 104. In one or more embodiments, the highvoltage DC splitter 123 may further include one or more inductor,capacitor, transformer, switch, DC filter, and/or regulator. A secondline out from the high voltage direct current terminal may be pulsewidth modulated by the dual inverter 112 to produce a modulated ACsignal for a corresponding electric motor 111.

With reference to FIG. 3, a first cooling system 118 is disposed to coolelectric motors 111. In FIG. 3, five electric motors 111 a-111 e areillustrated. Each electric motor 111 may include an associated scavengerpump 136, such as referenced above as auxiliary equipment, to pump thefirst coolant from its electric motor 111 into a collection manifold 137that is in fluid communication with a first coolant reservoir 130. Inone or more embodiments, the first coolant reservoir 130 includes alevel switch system 131 for monitoring and/or controlling the levels ofthe first coolant in the first coolant reservoir. In some embodiments,the first coolant is oil. A feed pump 132 may be utilized to draw thefirst coolant from the first coolant reservoir 130 and inject thecoolant from the first coolant reservoir 130 back to an electric motor111. A distribution manifold 134 may be employed to direct the firstcoolant to a plurality of electric motors 111. The first cooling system118 may include one or more sensors. The sensors may include, but arenot limited to, a temperature sensor 138, such as a thermistor, and apressure sensor 139. In any embodiment, the temperature sensor 138 maybe disposed in a thermowell. In any embodiment, the first cooling system118 may include one or more filters 133 for filtering the first coolant.

The second cooling system 120 may be utilized to cool dual inverters112. In FIG. 3, five dual inverters 112 a-112 e are illustrated. Thesecond coolant is pumped from a second coolant reservoir 140 by a secondcoolant pump 142 and supplied to a distribution manifold 144 thatsupplies the second coolant to each of the dual inverters 112 a-112 e.In one or more embodiments, the second coolant reservoir 140 includes alevel switch system 141 for monitoring and/or controlling the levels ofthe first coolant in the first coolant reservoir. In some embodiments,the second coolant is a mixture of water and glycol. In addition, thedistribution manifold 144 may supply the second coolant through anauxiliary distribution manifold 145 to one or more converters 124,inverters 125, and/or auxiliary components 126, as illustrated. Thesecond coolant may be collected from such auxiliary equipment through anauxiliary collection manifold 146. A collection manifold 147 may beemployed to collect the second coolant from the dual inverters 112 a-112e and the auxiliary collection manifold. Although the auxiliarydistribution and, collection manifolds 145, 146 are illustrated as partof the second cooling system 120, in one or more embodiments, thesecomponents may be included only in the first cooling system 118 and, inother embodiments, each of the first and second cooling systems 118, 120includes these components. As with the first cooling system 118 above,the second cooling system 120 may include one or more sensors. Thesensors may include, but are not limited to, a temperature sensor 148,such as a thermistor, and a pressure sensor 149. In any embodiment, thetemperature sensor 148 may be disposed in a thermowell. In anyembodiment, the second cooling system 120 may include one or morefilters 143 for filtering the first coolant. It will be appreciated thatthe pulse width modulation performed by the dual inverters 112 generatesa particularly large amount of heat, and that the second cooling system120 is desirable to maintain the temperature of dual inverters 112 a-112e at preferred operating temperatures.

Persons of ordinary skill in the art will appreciate that while it isnot shown, one or more heat transfer mechanisms may be utilized toremove heat from the first coolant and second coolant as is well knownin the art.

Referring to FIG. 4, a plurality of electric motors 111 a-111 e may bespaced around a central gearbox 113 including a gearset 114. Althoughfive electric motors 111 a-111 e are illustrated, the number of electricmotors 111 is not so limited. Electric motors 111 a-111 e may be evenlyspaced about the gearset 114, as shown in FIG. 4.

FIGS. 5a, 5b, 6a, 6b, and 6c provide various views of an electric drivehydraulic fracturing pump system 100 according to the presentdescription. In FIGS. 5a and 5b , transmission assemblies 105 aredisposed on opposing sides of power end 103 of the hydraulic frackingpump 101. In other embodiments, a single transmission assembly 105 maybe employed. As shown, each transmission assembly 105 may be coupled toa dual inverter assembly 110. Referring to FIG. 6a , a plurality ofcommunication lines 150 may be used to interconnect the variouscomponents of the electric drive hydraulic fracturing pump system 100,as described herein. The communication lines 150 may include electricalcables for carrying an electrical signal and/or hydraulic lines forcarrying coolant through the first or second cooling systems 118, 120.

Thus, a hydraulic fracturing pump system has been described. Thehydraulic fracturing pump system includes a hydraulic fracturing pumphaving a pump crankshaft; an electric drive motor coupled to the pumpcrankshaft; and an electric dual inverter electrically coupled to theelectric drive motor. In other embodiments, the hydraulic fracturingpump system may include a hydraulic fracturing pump having a pumpcrankshaft; a planetary gearset having an input shaft and an outputshaft, the output shaft coupled to the pump crankshaft; an electricdrive motor coupled to the input shall of the planetary gearset; and anelectric dual inverter electrically coupled to the electric drive motor.In yet other embodiments, a hydraulic fracturing pump system may includea hydraulic fracturing pump having a pump crankshaft extending along apump crankshaft axis; at least three electric drive motors coupled tothe power input shaft, each drive motor having an output axis alongwhich a drive motor output shaft extends, each of the three drive motorspositioned about the pump crankshaft axis so that each drive motoroutput shaft is spaced apart from the from the pump crankshaft axis; andat least three electric dual inverters, each dual inverter electricallycoupled to an electric drive motor. Still yet other hydraulic fracturingpump systems may include a hydraulic fracturing pump having a pumpcrankshaft extending along a pump crankshaft axis; at least threeelectric drive motors coupled to the pump crankshaft, each drive motorhaving an output axis along which a drive motor output shaft extends,each of the three drive motors positioned about the pump crankshaft axisso that each drive motor output shall is spaced apart from the from thepump crankshaft axis and from each other; and at least three electricdual inverters, each dual inverter electrically coupled to a separateelectric drive motor.

For any of the foregoing embodiments, the hydraulic fracturing pumpsystem may include any one of the following elements, alone or incombination with any other elements:

-   -   At least five electric drive motors coupled to the pump        crankshaft, each drive motor having an output axis along which a        drive motor output shaft extends, each of the five drive motors        positioned about the pump crankshaft axis so that each drive        motor output shaft is spaced apart from the from the pump        crankshaft axis; and at least five electric dual inverters, each        dual inverter electrically coupled to an electric drive motor.    -   At least five electric drive motors coupled to the pump        crankshaft, each drive motor having an output axis along which a        drive motor output shaft extends, each of the five drive motors        symmetrically positioned about the pump crankshaft axis so that        each drive motor output shaft is spaced apart from the from the        pump crankshaft axis and from each other; and at least five        electric dual inverters, each dual inverter electrically coupled        to a separate electric drive motor.    -   Each drive motor is symmetrically spaced about the pump        crankshaft axis.    -   The hydraulic pump further comprises a pump crankcase from which        the pump crankshaft extends, the hydraulic fracturing pump        system further comprising a drive motor support housing attached        to the pump crankcase.    -   The drive motor support housing is a gearbox.    -   A planetary gearset having an input shaft and an output shaft,        the output shaft coupled to the pump crankshaft of the hydraulic        fracturing pump and the input shaft. coupled to a drive motor        output shaft.    -   At least three planetary gearsets, each gearset having an input        shaft and an output shaft, the output shaft coupled to the pump        crankshaft of the hydraulic fracturing pump and each gearset        input shaft coupled to a drive motor output shaft.    -   A separate planetary gearset engaging each drive motor, each        gearset having an input shaft and an output shaft, the output        shaft coupled to the pump crankshaft of the hydraulic fracturing        pump and each gearset input shaft coupled to a drive motor        output shaft.    -   The hydraulic fracturing pump further comprises a pump crankcase        having a first end and a second end with a with a crankshaft        extending between the two crankcase ends along a crankshaft        axis, the crankshaft having a first end and a second end.    -   A separate electric drive motor coupled to each end of the pump        crankshaft; and a separate electric dual inverter electrically        coupled to each electric drive motor.    -   At least three planetary gearsets disposed at each end of the        crankcase, each gearset having an input shaft and an output        shaft, the output shaft coupled to the pump crankshaft end        adjacent the planetary gearset, each gearset input shaft coupled        to a drive motor output shaft.    -   At least three electric drive motors coupled to the pump        crankshaft at each end of the crankcase, each drive motor having        an output axis along which a drive motor output shaft extends,        each of the three drive motors at each crankcase end        symmetrically positioned about the pump crankshaft axis so that        each drive motor output shaft is spaced apart from the from the        pump crankshaft axis and from each other; and at least three        electric dual inverters at each end of the crankcase, each dual        inverter electrically coupled to a separate electric drive        motor.    -   Each drive motor comprises a drive motor housing, and each drive        motor housing has a dual inverter mounted thereon.    -   Each drive motor housing is substantially circular.    -   Each drive motor housing is substantially disk shaped.    -   Each dual inverter has a first alternating current input, a        first high voltage output, a first high voltage input and an        alternating current output.    -   A power source electrically coupled to the first alternating        current input of the dual inverter.    -   The alternating current output of the dual inverter is        electrically coupled to the electrical input of a drive motor.    -   The power source is a turbine electric generator.    -   An electric converter and a low voltage auxiliary electric        device electrically coupled to the electric converter, wherein        the high voltage output of the dual inverter is coupled to the        electric converter.    -   The low voltage auxiliary electric device is a pump.    -   The low voltage auxiliary electric device is a cooling fan.    -   An electric inverter and a low voltage auxiliary device oil        motor electrically coupled to the electric inverter, wherein the        high voltage output of the dual inverter is coupled to the        electric inverter.    -   A first cooling system having a first cooling fluid and a second        cooling system having a second cooling fluid.    -   The first cooling system is fluidically coupled to a drive motor        and the second cooling system is fluidically coupled to a dual        inverter.    -   The first cooling fluid is oil and the second cooling fluid is a        glycol and water mixture.    -   The first cooling system is fluidically coupled to each drive        motor and the second cooling system is fluidically coupled to        each dual inverter.    -   The motor has a cooling fluid inlet and a cooling fluid outlet    -   The dual inverter has a cooling fluid inlet and a cooling fluid        outlet    -   A first fluid reservoir and a first fluid pump fluidically        coupled thereto, wherein the cooling fluid inlet of the motor is        fluidically coupled to the first fluid pump and the cooling        fluid outlet of the motor is fluidically coupled to the first        fluid reservoir.    -   A scavenger pump fluidically coupled between the cooling fluid        outlet of the motor and the first fluid reservoir.    -   A second fluid reservoir and a second fluid pump fluidically        coupled thereto, wherein the cooling fluid inlet of the dual        inverter is fluidically coupled to the second fluid pump and the        cooling fluid outlet of the dual inverter is fluidically coupled        to the second fluid reservoir.    -   The electric inverter is fluidically coupled to the second        reservoir.    -   The low voltage auxiliary device oil motor is fluidically        coupled to the second reservoir.

Thus, a method for operating a hydraulic fracturing pump has beendescribed. In one or more embodiments, the method generally incudesutilizing a first dual inverter to supply electrical current to a firstelectric motor; energizing a first electric motor to initiate rotationof hydraulic fracturing pump crankshaft; and thereafter utilizing asecond dual inverter to supply electrical current to a second electricmotor; and energizing the second electric motor to provide power to thepump crankshaft. In other embodiments, the method includes energizing afirst electric motor to initiate rotation of hydraulic fracturing pumpcrankshaft; and utilizing a dual inverter to dynamically control theelectric motor to adjust power to the pump crankshaft. In otherembodiments, the method includes energizing a plurality of electricmotors to rotate a hydraulic fracturing pump crankshaft; and utilizing aplurality of dual inverters to separately control the electric motors toadjust power to the pump crankshaft. In other embodiments, the methodmay include utilizing a first dual inverter to energize a first electricmotor to initiate rotation of hydraulic fracturing pump crankshaft; andthereafter utilizing a second dual inverter and a third dual inverter toenergizing at least a second electric motor and a third electric motor,respectively, to provide power to the pump crankshaft.

For the foregoing embodiments, the method may include any one of thefollowing steps, alone or in combination with each other:

-   -   Measuring a condition of the hydraulic fracturing pump and based        on the measured condition, energizing at least a second electric        motor and a third electric motor to provide power to the pump        crankshaft.    -   Measuring a condition of the hydraulic fracturing pump and based        on the measured condition, energizing at least a fourth electric        motor and a fifth electric motor to provide power to the pump        crankshaft.    -   Measuring a condition of the hydraulic fracturing pump and based        on the measured condition, dynamically controlling a plurality        of electric motors to adjust power to the pump crankshaft.    -   Dynamically controlling a plurality of electric motors to adjust        power to the pump crankshaft.    -   Separately controlling a plurality of electric motors to adjust        power to the pump crankshaft.    -   Rectifying an input alternating current from a power source to a        high voltage direct current; and thereafter, reducing the        average power delivered by high voltage direct current through        pulse width modulation to generate a pulse width modulation        signal; and energizing the first electric motor utilizing the        pulse width modulation signal.    -   Utilizing a power source to provide an alternating current to a        hydraulic fracturing pump system; rectifying the alternating        current to a high voltage direct current; and thereafter,        reducing the average power delivered by high voltage direct        current through pulse width modulation to generate a pulse width        modulation signal; and energizing the first electric motor        utilizing the pulse width modulation signal.    -   Utilizing a power source to provide an alternating current to a        hydraulic fracturing pump system having a plurality of electric        motors; separately for each electric motor, (i) rectifying the        alternating current to a high voltage direct current; (ii)        reducing the average power delivered by high voltage direct        current through pulse width modulation to generate a pulse width        modulation signal; and (iii) energizing the electric motor        utilizing the pulse width modulation signal.

It is apparent that an invention with significant advantages has beendescribed and illustrated. The particular embodiments disclosed aboveare illustrative only, as the invention may be modified and practiced indifferent but equivalent manners apparent to those skilled in the arthaving the benefit of the teachings herein. It is therefore evident thatthe particular embodiments disclosed above may be altered or modified,and all such variations are considered within the scope and spirit ofthe invention. Accordingly, the protection sought herein is as set forthin the description. Although the present invention is shown in a limitednumber of forms, it is not limited to just these forms, but is amenableto various changes and modifications without departing from the spiritthereof.

1. A hydraulic fracturing pump system comprising: a hydraulic fracturingpump having a pump crankshaft and a pump crankcase having a firstcrankcase end and a second crankcase end with the pump crankshaftextending between the first and second crankcase ends; a plurality ofelectric drive motors, each electric drive motor having a motor housingand a separate drive motor output shaft coupled to the pump crankshaft;a plurality of electric dual inverters, each electric dual invertermounted on one of the plurality of electric drive motors, each electricdual inverter having an inverter housing and each dual inverterelectrically coupled to a separate one of the plurality of electricdrive motors; and a gearbox assembly adjacent one of the first or secondcrankcase ends, the gearbox assembly comprising a gearset enclosed by agearbox housing; wherein each motor housing is mounted on the gearboxhousing; and wherein each inverter housing is externally mounted on amotor housing.
 2. The hydraulic fracturing pump system of claim 1,wherein the gearset is a planetary gearset; wherein each electric drivemotor is coupled to the planetary gearset.
 3. The hydraulic fracturingpump system of claim 1, wherein the pump crankshaft extends along a pumpcrankshaft axis; wherein the plurality of electric drive motorscomprises at least three electric drive motors coupled to the pumpcrankshaft, each of the at least three electric drive motors having aseparate output axis along which a drive motor output shaft extends,each of the at least three electric drive motors positioned about thepump crankshaft axis so that each drive motor output shaft of the atleast three electric drive motors is spaced apart from the from the pumpcrankshaft axis and the other drive motor output shafts; and wherein theplurality of electric dual inverters comprises at least three electricdual inverters, each of the at least three electric dual inverterselectrically coupled to a separate one of the at least three electricdrive motors, each dual inverter housing of the at least three electricdual inverters mounted on the motor housing of a separate one of the atleast three electric drive motors so that each of said at least threeelectric dual inverters is substantially positioned along the outputaxis of the electric drive motor on which said electric dual inverter ismounted.
 4. The hydraulic fracturing pump system of claim 1, wherein thepump crankshaft extends along a pump crankshaft axis; wherein theplurality of electric drive motors comprises at least five electricdrive motors coupled to the pump crankshaft, each of the at least fiveelectric drive motors having a separate output axis along which a drivemotor output shaft extends, each of the at least five electric drivemotors positioned about the pump crankshaft axis so that each drivemotor output shaft of the at least five electric drive motors is spacedapart from the from the pump crankshaft axis and the other drive motoroutput shafts; and wherein the plurality of electric dual inverterscomprises at least five electric dual inverters, each of the at leastfive electric dual inverters electrically coupled to a separate one ofthe at least five electric drive motors, each dual inverter housing ofthe at least five electric dual inverters mounted on the motor housingof a separate one of the at least five electric drive motors so thateach of said at least five electric dual inverters is substantiallypositioned along the output axis of the electric drive motor on whichsaid electric dual inverter is mounted.
 5. The hydraulic fracturing pumpsystem of claim 4, wherein each electric drive motor of the at leastfive electric drive motors is symmetrically spaced about the pumpcrankshaft axis so that each electric dual inverter of the at least fivedual inverters is mounted on a separate one of the at least fiveelectric drive motors so as to be spaced apart from the other electricdual inverters.
 6. The hydraulic fracturing pump system of claim 1,wherein each electric drive motor of the plurality of electric drivemotors has a separate output axis along which its drive motor outputshaft extends; and wherein each electric dual inverter of the pluralityof electric dual inverters is mounted on a motor housing of a separateone of the plurality of electric drive motors so that each of saidplurality of electric dual inverters is substantially positioned alongthe output axis of the electric drive motor on which said electric dualinverter is mounted.
 7. The hydraulic fracturing pump system of claim 6,wherein each electric dual inverter of the plurality of electric dualinverters is electrically coupled to the electric drive motor on whichsaid electric dual inverter is mounted.
 8. A hydraulic fracturing pumpsystem comprising: a hydraulic fracturing pump having a pump crankshaftextending along a pump crankshaft axis and a pump crankcase having afirst crankcase end and a second crankcase end with the pump crankshaftextending between the first and second crankcase ends along thecrankshaft axis, the pump crankshaft having a first crankshaft end and asecond crankshaft end; a planetary gearset having an input shaft and anoutput shaft, the output shaft coupled to the pump crankshaft; a gearboxhousing enclosing the planetary gearset; a plurality of electric drivemotors, each electric drive motor having a separate drive motor outputshaft coupled to the input shaft of the planetary gearset and eachelectric drive motor having a motor housing mounted on the gearboxhousing; a plurality of electric dual inverters, each electric dualinverter mounted on one of the plurality of electric drive motors, eachelectric dual inverter having an inverter housing attached externally tothe motor housing of a separate one of the plurality of electric drivemotors, and each dual electric inverter electrically coupled to aseparate one of the plurality of electric drive motors.
 9. The hydraulicfracturing pump system of claim 8, further comprising: a gearbox housingattached to each crankcase end of the pump crankcase, with a portion ofthe plurality of electric drive motors mounted on each gearbox housing.10. The hydraulic fracturing pump system of claim 8, wherein theplurality of electric drive motors comprises at least three electricdrive motors coupled to the pump crankshaft at each crankcase end of thecrankcase, each one of the at least three electric drive motors having adrive motor output shaft and an output axis along which said drive motoroutput shaft extends, the at least three electric drive motors at eachcrankcase end symmetrically positioned about the pump crankshaft axis sothat the drive motor output shaft of each of the at least three electricdrive motors at a crankcase end is spaced apart from the from the pumpcrankshaft axis and from the other drive motor output shafts at saidcrankcase end; and wherein the plurality of electric dual inverterscomprises at least three electric dual inverters at each crankcase endof the crankcase, each one of the at least three electric dual inverterselectrically coupled to a separate one of the at least three electricdrive motors at a crankcase end and electrically independent of theother electric dual inverters, each dual inverter housing of the atleast three electric dual inverters at each crankcase end mounted on themotor housing of the plurality of electric drive motors so that each ofsaid at least three electric dual inverters at each crankcase end issubstantially positioned along the output axis of the electric drivemotor on which said electric dual inverter is mounted.
 11. The hydraulicfracturing pump system of claim 8, wherein each of the plurality ofelectric dual inverters is electrically coupled to the electric drivemotor on which said electric dual inverter is mounted.
 12. The hydraulicfracturing pump system of claim 8, wherein each electric dual inverterhas a first alternating current input, a first direct current voltageoutput of a first magnitude, a first direct current voltage input of thefirst magnitude and an alternating current output; and wherein thealternating current output of each electric dual inverter iselectrically coupled to an electrical input of its electric drive motor.13. The hydraulic fracturing pump system of claim 12, furthercomprising: an electric converter and an auxiliary electric device of adirect current voltage of a second magnitude less than the firstmagnitude electrically coupled to the electric converter, wherein aplurality of first direct current voltage outputs of the plurality ofelectric dual inverters is coupled to the electric converter and whereinthe auxiliary electric device is a pump or a cooling fan.
 14. Thehydraulic fracturing pump system of claim 12, further comprising: anelectric DC to AC inverter and an auxiliary electric device electricallycoupled to the electric DC to AC inverter and powered by the electric DCto AC inverter, wherein one or more of first direct current voltageoutputs of the plurality of electric dual inverters is coupled to theelectric DC to AC inverter.
 15. The hydraulic fracturing pump system ofclaim 8, further comprising: a first cooling system having a firstcooling fluid and a second cooling system having a second cooling fluid.16. The hydraulic fracturing pump system of claim 15, wherein the firstcooling fluid is oil and the second cooling fluid is a glycol and watermixture.
 17. The hydraulic fracturing pump system of claim 15, Whereinthe first cooling system is fluidically coupled to each of the pluralityof electric drive motors and the second cooling system is fluidicallycoupled to each of the plurality of electric dual inverters; whereineach electric drive motor of the plurality of electric drive motors hasa cooling fluid inlet and a cooling fluid outlet; and wherein eachelectric dual inverter of the plurality of electric dual inverters has acooling fluid inlet and a cooling fluid outlet.
 18. The hydraulicfracturing pump system of claim 17, further comprising: a first fluidreservoir and a first fluid pump fluidically coupled thereto, whereinthe cooling fluid inlet of each electric drive motor of the plurality ofelectric drive motors is fluidically coupled to the first fluid pump andthe cooling fluid outlet of each electric drive motor of the pluralityof electric drive motors is fluidically coupled to the first fluidreservoir; and a second fluid reservoir and a second fluid pumpfluidically coupled thereto, wherein the cooling fluid inlet of eachelectric dual inverter of the plurality of electric dual inverters isfluidically coupled to the second fluid pump and the cooling fluidoutlet of each electric dual inverter of the plurality of electric dualinverters is fluidically coupled to the second fluid reservoir.
 19. Thehydraulic fracturing pump system of claim 8, wherein each electric dualinverter of the plurality of electric dual inverters has a firstalternating current input, a first direct current voltage output of afirst magnitude, an alternating current output; and wherein thealternating current output of each electric dual inverter iselectrically coupled to an electrical input of the electric drive motorto which said electric dual inverter is mounted; the hydraulicfracturing pump system further comprising: an electric DC to ACinverter, an auxiliary electric device electrically coupled to theelectric DC to AC inverter and powered by the electric DC to ACinverter, wherein one or more of first direct current voltage outputs ofthe plurality of electric dual inverters is electrically coupled to theelectric DC to AC inverter; a first cooling system having a firstcooling fluid, wherein the first cooling system is fluidically coupledto each electric drive motor of the plurality of electric drive motorsand wherein each electric drive motor of the plurality of electric drivemotors has a cooling fluid inlet and a cooling fluid outlet; a secondcooling system having a second cooling fluid, wherein the second coolingsystem is fluidically coupled to each electric dual inverter of theplurality of electric dual inverters and wherein each electric dualinverter of the plurality of electric dual inverters has a cooling fluidinlet and a cooling fluid outlet; a first fluid reservoir and a firstfluid pump fluidically coupled thereto, wherein the cooling fluid inletof each electric drive motor of the plurality of electric drive motorsis fluidically coupled to the first fluid pump and the cooling fluidoutlet of each electric drive motor of the plurality of electric drivemotors is fluidically coupled to the first fluid reservoir; a secondfluid reservoir and a second fluid pump fluidically coupled thereto,wherein the cooling fluid inlet of each electric dual inverter of theplurality of electric dual inverters is fluidically coupled to thesecond fluid pump and the cooling fluid outlet of each electric dualinverter of the plurality of electric dual inverters is fluidicallycoupled to the second fluid reservoir; and a scavenger pump fluidicallycoupled between the cooling fluid outlet of each electric drive motorand the first fluid reservoir, wherein at least one of the first fluidpump, the second fluid pump and the scavenger pump is electricallycoupled to the electric DC to AC inverter and powered by the electric DCto AC inverter.
 20. The hydraulic fracturing pump system of claim 19,further comprising a plurality of scavenger pumps, each scavenger pumpseparately fluidically coupled to a separate one of the electric drivemotors of the plurality of electric drive motors, and wherein theelectric DC to AC inverter is electrically coupled to the plurality ofelectric dual inverters and powers each of the first fluid pump, thesecond fluid pump and the plurality of scavenger pumps.
 21. A method foroperating a hydraulic fracturing pump comprising: energizing a firstelectric drive motor to initiate rotation of hydraulic fracturing pumpcrankshaft; thereafter energizing a plurality of separate electric drivemotors to provide additional power to the pump crankshaft; individuallycontrolling each of the plurality of electric drive motors separate fromeach of the other electric drive motors to adjust power to the pumpcrankshaft, wherein individually controlling comprises: utilizing apower source to provide an alternating current to a hydraulic fracturingpump system; and individually for each separate electric drive motor,(i) rectifying the alternating current to a high voltage direct current;(ii) reducing the average power delivered by high voltage direct currentthrough pulse width modulation to generate a pulse width modulationsignal; and (iii) powering the electric drive motor utilizing the pulsewidth modulation signal.
 22. The method of claim 21, further comprising:measuring a condition of the hydraulic fracturing pump; and based on themeasured condition, dynamically controlling and powering each of theplurality of electric drive motors individually with a separate electricdual inverter to adjust power to the pump crankshaft.
 23. The method ofclaim 22, further comprising: individually controlling each of theplurality of electric drive motors separate from each of the otherelectric drive motors to adjust power to the pump crankshaft.
 24. Themethod of claim 23, wherein individually controlling comprises utilizinga power source to provide an alternating current to a hydraulicfracturing pump system; and individually for each electric drive motor,(i) rectifying the alternating current to a high voltage direct current;(ii) reducing the average power delivered by high voltage direct currentthrough pulse width modulation to generate a pulse width modulationsignal; and (iii) energizing the electric drive motor utilizing thepulse width modulation signal.
 25. A method for operating a hydraulicfracturing pump comprising: energizing a first electric drive motor oinitiate rotation of hydraulic fracturing pump crankshaft; dynamicallycontrolling a plurality of electric drive motors to adjust power to thepump crankshaft; utilizing a power source to provide an alternatingcurrent to the hydraulic fracturing pump system having a plurality ofelectric drive motors and a plurality of electric dual inverters;separately for each electric drive motor controlling operation of theelectric drive motor utilizing a separate electric dual inverter by (i)rectifying the alternating current to a high voltage direct current;(ii) reducing the average power delivered by high voltage direct currentthrough pulse width modulation to generate a pulse width modulationsignal; and (iii) powering the electric drive motor utilizing the pulsewidth modulation signal.
 26. The method of claim 25, further comprising:measuring a condition of the hydraulic fracturing pump; and based on themeasured condition, energizing at least a second electric drive motorand a third electric drive motor to provide power to the pumpcrankshaft.
 27. The method of 26, further comprising: measuring acondition of the hydraulic fracturing pump; and based on the measuredcondition, energizing at least a fourth electric drive motor and a fifthelectric drive motor to provide power to the pump crankshaft.
 28. Themethod of claim 25, further comprising: separately and individuallypowering and controlling each of the plurality of electric drive motorsto adjust power to the pump crankshaft.
 29. The method of claim 25,further comprising: rectifying an input alternating current from a powersource to a high voltage direct current; thereafter, reducing theaverage power delivered by high voltage direct current through pulsewidth modulation to generate a pulse width modulation signal; andenergizing the first electric drive motor utilizing the pulse widthmodulation signal.
 30. The method of claim 25, further comprising:utilizing a power source to provide an alternating current to ahydraulic fracturing pump system having a plurality of electric motors;separately for each electric drive motor, (i) rectifying the alternatingcurrent to a high voltage direct current; (ii) reducing the averagepower delivered by high voltage direct current through pulse widthmodulation to generate a pulse width modulation signal; and (iii)energizing the electric drive motor utilizing the pulse width modulationsignal.